Gas supply unit and valve used therein



' A ril 26, 1966 R. B. REMICK, JR.. ETAL 3,248,058

GAS SUPPLY UNIT AND VALVE USED THEREIN Filed 001;. '7, 1963 mmmsmr Fl [3 E] 0/? YER INVENTORS PEN/CA, J2. Amy/WWO 6'. Axvamsaw BY MEL Wm M! POZK/Nqfi/OAN Pam 5.

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United States Patent 3,248,058 GAS SUPPLY UNIT AND VALVE USED THEREIN Ralph Barrier Reinick, .ln, Detroit, and Melvin William Pollringhorn, Livonia, Mich, and Maynard Eldridge Anderson, Pleasanton,- Calif., assignors to American Radiator 8; Standard Sanitary Corporation, New York, N.Y., a corporation of Delaware Filed Oct. 7, 1963, Ser. No. 314,407 3 Claims. (Cl. 236-92) "This invention relates to a fuel supply unit, and to a solenoid shut-off valve used therein.

In certain recently devised gas-fired domestic clothes driers the burner is ignited electrically, and is supplied with *varying quantities of fuel gas during different operational periods. At initial ignition the fuel supply unit furnishes the burner with large quantities of fuel gas to quickly bring the drier up to operating temperature. Thereafter a thermostat in the drier automatically cycles the gas supply unit between low fire and high fire positions to maintain the desired operating temperature throughout the drying cycle.

One object of this invention is to provide a low cost gas supply unit which automatically feeds gas to the burner in accordance with the above specified high fire and low fire requirements.

A further object is to provide a gas supply unit which includes a pressure regulator as an integral component thereof, whereby to prevent flow deviations from the high fire and low fire fuel quantities.

Another object is to provide a fuel gas supply unit which is manufacturable as a relatively compact unit capable of being installed in conventional domestic clothes driers.

An additional object is to provide a gas supply unit having a relatively low cost shut-off valve incorporated therein.

Other objects of this invention will appear from the following description and appended claims, reference being had to the accompanying drawings forming a part of this specification wherein like reference characters designate corresponding parts in the several views.

In the drawings:

FIGURE 1 is a vertical sectional view taken through a fuel gas supply unit constituting one embodiment of the invention;

FIG. 2 is a plan view of the FIG. 1 unit taken on a reduced scale; and

FIG. 3 is a diagram of suitable circuitry for controlling the FIG. 1 gas supply unit.

Before explaining the present invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and arrangement of parts illustrated in the accompanying drawings, since the invention is capable of other embodiments and of being practiced or carried out in various ways. Also, it is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation.

In the drawings there is shown a fuel gas supply unit comprising an upright die cast housing having an integral hollow projection 11 which is internally threaded to receive a gas supply pipe (not shown). The housing provides a fuel gas inlet chamber 12, an intermediate chamber 14, and an outlet chamber 16. Chamber 12 accommodates a rubber valve element 15 which is carried on a vertical stem 18 extending downwardly from a flexible diaphragm 20. Element 15 is preferably of sufficient flexibility and dimension as to permit its being installed by a downward movement through port 13, preferably after diaphragm 20 is positioned on the housing upper 'ice face. Retention of the diaphragm is accomplished by a suitable cover 22 which also functions to house the adjustable regulator spring 26.

In the illustrated construction the regulator spring is trained between diaphragm 20 and an annular retainer element 28 having threaded engagement with the threads of an adjustment screw 30. The opposite end convolutions of spring 26 are tightly affixed to the diaphragm and retainer element 28, respectively, so that manual rotation of screw 30 is effective to vary the spring loading on diaphragm 20 and thus adjust the regulated pressure in chamber 14.

During service diaphragm 20 responds to slight varitions in the pressure within chamber 14 to operate element 15 vertically and thus vary the flow through port 13. The result is a stabilized pressure in chamber 14 in spite of wide pressure fluctuations in the gas supplied to chamber 12.

Extending downwardly from chamber 14 is a cylindrical pocket 32, in which is suspended an elastomeric cup 34. As shown in the drawing the cup is provided with a relatively thin side wall 36 and a relatively thick bottom wall 38 having a flow passage 42 extending therethrough. The upper portion of the cup is provided with a peripheral flange 40 which seats in an annular recess in housing 10 to suspend the cup within pocket 32. The cup wall 38 is spaced from the subjacent housing surface so that any irregularities in housing configuration are ineffective to prevent flow passage 42 from forming a truly circular seat for the ball valve element 44. The ball valve element is of magnetic material and constitutes an armature for the solenoid designated generally by numeral 46.

The illustrated solenoid comprises a magnetic postlike core element 50, a magnetic frame 52, Wire turns 54, and dielectric encapsulating sheath 56. During manufacture of the unit wire turns 54 are encapsulated within the molded dielectric sheathing 56 to form an annular coil unit. Thereafter the post is inserted as a press fit within an opening in the wall of housing 10, the molded coil is inserted on core element post 50, and bracket 52 is secured on an exterior surface of housing 10, as by a screw 53. The bracket 52 is of L-shaped configuration, with leg thereof having an aperture to receive the reduced diameter end portion of post 50.

During operation of the gas supply unit, energization of solenoid 46 causes armature ball 44 to be drawn upwardly from its full line position toward its dotted line position, to thus provide a path for the flow of fuel gas from intermediate chamber 14 to outlet chamber 16. It will be noted that passage 42 is offset from the axis of cylindrical cup 34 in the direction of solenoid 46. The hall 44 is thus spaced from the left portion of cup side wall 36 so that a relatively large cross sectional flow path is provided to the left of the ball when the ball is attracted toward core 50. The offsetting of flow passage 42 also is advantageous in disposing the ball relatively close to core 50 when the ball is in the closed full line position. There is thus a relatively small gap between the ball and core, which permits use of a relatively small low cost solenoid.

Preferably the tip of core 50 is slightly recessed from the side wall surface of pocket 32, and the side Wall 36 of the cup is spaced inwardly from the surface of pocket 32. Such an arrangement is advantageous at the moment when the solenoid is energized in that it enables ball 44 to seek out core 50 without oscillating vertically. The arrangement is also advantageous at the moment when the solenoid is de-energized in that it sets up a horizontally acting resilient force in wall 36 tending to dislodge ball 44 from core 56. This resilient force counteracts the effects of residual magnetism in the core and ball.

Disposed within outlet chamber 16 in press fit relation is a sleeve 57 having a reduced diameter extension 58 which mounts an orifice member W. The joint between sleeve 57 and the surface of chamber 16 may be suitably sealed by an O-ring 62:. In the illustrated construction sleeve 57 houses a wire coil element 64 which has its opposite end portions spiralled inwardly to form circular ring-like guides 66 and 6% for a cylindrical metering element 7 The use of a wire guide element is advantageous in that it provides very little obstruction to the gas flow.

To move the metering element there is provided a second solenoid 46a having an encapsulated coil section 54a and a core which is located in axial alignment with the metering element. The metering element is preferably provided with a rubber bumper 72 which eliminates the noise which would otherwise occur when the element is drawn toward core 50a. A compression coil spring 74 is provided to advance the metering element leftward when the solenoid is de-energized. At its left end the metering element is provided with a conical tip having a flattened surface 80. As a result of this construction de-energization of solenoid 46a causes the metering element to move to the dotted line position in which a small restricted flow of gas is permitted through orifice 76. If desired the metering element can be operated by a thermostatic bulb responsive to the demand for heat. The essential feature is the employment of an operating means which moves the metering element toward orifice '76 as the demand for heat lessens and away from orifice 76 as the demand for heat increases.

As previously noted, this gas supply unit is particularly useful for supplying fuel gas to the burner of a gas fired domestic clothes drier. Preferably the unit discharges directly into the gas burner as shown in FIG. 3 of the US. Patent 3,090,423. In the instant drawing a portion of the gas burner is shown at 82.

When this valve is utilized in a domestic clothes drier the control circuit is preferably arranged to initially energize both solenoids 46 and 46a. The amount of gas supplied to the burner is thus determined by the setting of regulator spring 26 and the size of orifice '76. Passage 42 is relatively large and exerts no restricting action on the gas flow.

The metering element solenoid 46a is preferably controlled by a drier thermostat which is arranged to deenergize the metering element solenoid upon the attainment of a satisfactory drying temperature. The metering element is thus moved to its dotted line position to reduce the effective size of orifice '76 and thereby reduce the flow of fuel gas into the burner.

During the drying cycle the gas supply unit initially feeds relatively large quantities of gas to the burner to enable the burner to quickly bring the clothes drier up to operating temperature. Thereafter the drier thermostat causes solenoid 46a to cycle the metering element between maximum flow and minimum flow positions to maintain the desired operating temperature. During nonoperational periods ball 44 completely seals against fiow of gas to the burner.

Various non-illustrated control devices and circuits may be used to control the operations of igniting the fuel, guarding against flame-extinguishment, and controlling the duration of the heating cycle. For illustration purposes FIG. 3 of the instant drawings shows a fuel supply control circuit wherein a control device 84, such as one or more switches, controls the two solenoid windings 54 anc Winding 54 is additionally controlled by a dryer thermostat 86. Thus, the dryer thermostat is able when satisfied to de-energize winding 54a and thus allow metering element 79 to move to the low fire position.

One particular advantage in the illustrated construction derives from the fact that a single die cast housing element lltl can be utilized to mount pressure regulator 241*, main shut-off valve 44, and metering valve 7t By this arrangement the number of pipe joints and housing components is considerably reduced.

The particular unit shown in the drawing is especially interesting in that housing 10 can be formed as a onepiece die casting. Thus, chamber 14 can be formed by a cavity cast into the upper face of the housing, and outlet chamber 16 can be formed by a second cavity cast into one of the housing side faces.

To adapt the supply unit for clothes drier use the unit is formed with inlet 12 arranged at right angles to the discharge orifice 76. In most conventional clothes driers the burner is arranged in a lower portion of the drier housing to direct the flame along a front-to-rear axis. The gas supply line extends from the rear wall of the drier housing forwardly and thence laterally to the fuel gassupply unit. When the illustrated gas supply unit is utilized inlet chamber 12 can be connected directly with the laterally extending portion of the gas supply line, and orifice member 60 can be connected directly with the burner.

It is believed that some advantage may be derived by forming the gas supply unit with the two solenoids 46 and 46a disposed in a side surface of housing 10. This disposition of parts provides a compact construction in which the vertical and horizontal dimensions are substantially the same. Most present gas driers will accommodate this body configuration, whereas some difiiculties might be encountered in accommodating other shapes, particularly pancake configurations in which the shut-off valve element and metering element are disposed in upright positions in horizontal alignment with the regulator components.

One further advantageous feature of the illustrated arrangement is the fact that each of valve elements 44 and 70 is substantially noiseless during valve element movement. Thus, element as is arranged within an elastomeric cup 34, which acts to suppress noise as the valve element is attracted toward core 5%. Similarly, metering element 70 is provided with an elastomeric bumper element 72 which dampens noise as the element is drawn toward its core 50a.

What is claimed:

ll. A fuel gas supply unit comprising a main housing having in series an inlet chamber, an intermediate chamber, an outlet chamber, and an outlet orifice; a first valve seat between the intermediate chamber and the outlet chamber; a pressure regulator diaphragm positioned on one face of the housing in a location facing the intermediate chamber, a first valve element within the inlet chamber, and a stem interconnecting the diaphragm and first valve element for causing the element to move toward and away from the first valve seat to thus provide a substantially constant gas pressure in the intermediate chamber in spite of pressure fluctuations in the inlet chamher; a second shut-off valve element cooperating with the second valve seat to control gas flow to the outlet chamber; a metering element disposed in the outlet chamber for movement toward and away from the outlet orifice, whereby to assume a first position permitting full fiow of gas through the orifice and a second position permitting restricted flow of gas through the orifice, means for operating the shut-off valve element comprising a first solenoid coil positioned on a second face of the main housing; and means for operating the metering element comprising a second solenoid coil positioned on said second face of the main housing closely alongside the first solenoid coil.

2. A fuel gas supply unit comprising a housing having first, second and third faces arranged at right angles to one another, and a fourth face arranged parallel to the third face; a first gas passage extending into the housing from the first housing face and defining an inlet chamber; a first cavity formed in the second housing face and defining an intermediate chamber; a port interconnecting the inlet chamber and intermediate chamber and defining a first valve seat; a pressure regulator diaphragm seated on the second housing face and forming one wall of the intermediate chamber; a first valve element disposed within the inlet chamber, and a stem interconnecting the diaphragm and first valve element, whereby the pressure in the intermediate chamber is stabilized in spite of pressure variations in the inlet chamber; a pocket extending inwardly from the intermediate chamber generally parallel to the third housing face; a second valve seat disposed in said pocket, and a valve element fioatably arranged adjacent the second valve seat to control flow therethrough; a second cavity formed in the four housing face and defining an outlet chamber in fluid communication with the second valve seat; an outlet orifice wall means extending across the outlet chamber; and a metering element floatably disposed within the outlet chamber for movement between a first full flow position located away from the outlet orifice and a second restricted flow position located adjacent the outlet orifice.

3. A fuel gas supply unit for a burner comprising an upright housing having a first horizontal gas passage extending into the housing and defining an inlet chamber; a first cavity formed in the upper face of the housing and defining an intermediate chamber; a port interconnecting the inlet chamber and intermediate chamber and defining a first valve seat; a pressure regulator diaphragm seated on the housing upper face and forming the upper wall of the intermediate chamber; a first valve element dis posed within the inlet chamber below the diaphragm, and a stem interconnecting the diaphragm and first valve element, whereby the pressure in the intermediate chamber is stabilized in spite of pressure variations in the inlet chamber; a pocket extending downwardly from the intermediate chamber; an elastomeric cup suspended within the pocket, and a fiow passage extending through the cup bottom Wall to form a second valve seat; a second gravitybiased valve element arranged within the cup to normally engage the second valve seat, and solenoid means operable to move the second valve element away from the second valve seat to permit flow of gas therethrough; a second horizontal cavity formed in a side face of the housing and defining an outlet chamber in fiuid communication with the second valve seat; an outlet orifice wall means extending across the outlet chamber; a metering element disposed Within the outlet chamber; and means responsive to demand on the burner for moving the metering element between a first full flow position located away from the outlet orifice and a second restricted flow position located adjacent the outlet orifice.

References Cited by the Examiner UNITED STATES PATENTS 1,874,971 8/1932 Hall et al 2361 2,020,710 11/1935 Warner 137-613 2,608,349 8/1952 Landgraf et al 236-l 2,887,294 5/ 1959 Hahn 251129 2,905,389 9/1959 Eskin 23692 2,919,858 1/1960 Matthews 236-1 3,013,768 12/1961 La Mastra 251-129 3,050,255 8/1962 Willson et al 2361 3,084,865 4/1963 Fleer et al. 236-99 JAMES W. WESTHAVER, Primary Examiner. FREDERICK L. MATTESON, ]R., Assistant Examiner. 

1. A FUEL GAS SUPPLY UNIT COMPRISING A MAIN HOUSING HAVING IN SERIES AN INLET CHAMBER, AN INTERMEDIATE CHAMBER, AN OUTLET CHAMBER, AND AN OUTLET ORIFICE; A FIRST VALVE SEAT BETWEEN THE INTERMEDIATE CHAMBER AND THE OUTLET CHAMBER; A PRESSURE REGULATOR DIAPHRAGM POSITIONED ON ONE FACE OF THE HOUSING IN A LOCATION FACING THE INTERMEDIATE CHAMBER, A FIRST VALVE ELEMENT WITHIN THE INLET CHAMBER, AND A STEM INTERCONNECTING THE DIAPHRAGM AND FIRST VALVE ELEMENT FOR CAUSING THE ELEMENT OF MOVE TOWARD AND AWAY FROM THE FIRST VALVE SEAT TO THUS PROVIDE A SUBSTANTIALLY CONSTANT GAS PRESSURE IN THE INTERMEDIATE CHAMBER IN SPITE OF PRESSURE FLUCTUATIONS IN THE INLET CHAMBER; A SECOND SHUT-OFF VALVE ELEMENT COOPERATING WITH THE SECOND VALVE SEAT TO CONTROL GAS FLOW TO THE OUTLET CHAMBER; A METERING ELEMENT DISPOSED IN THE OUTLET CHAMBER FOR MOVEMENT TOWARD AND AWAY FROM THE OUTLET ORIFICE, WHEREBY TO ASSUME A FIRST POSITION PERMITTING FULL FLOW OF GAS THROUGH THE ORIFICE AND A SECOND POSITION PERMITTING RESTRICTED FLOW OF GAS THROUGH THE ORIFICE, MEANS FOR OPERATING THE SHUT-OFF VALVE ELEMENT COMPRISING A FIRST SOLENOID COIL POSITIONED ON A SECOND FACE OF THE MAIN HOUSING; AND MEANS FOR OPERATING THE METERING ELEMENT COMPRISING A SECOND SOLENOID COIL POSITIONED ON SAID SECOND FACE OF THE MAIN HOUSING CLOSELY ALONGSIDE THE FIRST SOLENOID COIL. 